Rug and method of making same



Nov. 16, 1937. W W, ROBINSQN 2,099,626

RUG AND METHOD OF MAKING SAME Filed Nov. 19, 193e 2 sheets-sheet 1 Nov. 16, 1937. W, W ROBlNSoN 2,099,626

RUG AND METHOD OF MAKING SAME Filed Nov. 19, 1956 2 Sheets-Sheet 2 -Patented Nov. 16, 1937 UNITED STATES PATENT OFFICE to McCallum & Robinson, Inc., Memphis Tenn.,

a corporation of Tennessee Application November 19, 1936, Serial No. 111,722

9 Claims.

This invention relates to rugs, and has for one of its objects the production of a rug or mat of simple construction which may be made on a sewing machine thereby eliminating the use of 5 a loom which is usually necessary in the construction of rugs, mats and the like.

A further object of this invention is the production of a rug or mat wherein the yarn used in the construction of the rug is stitched to the 10 base of the rug by means of a plurality of spaced rows of stitching extending longitudinally of the base and transversely of the strands of yarn.

Another object of this invention is the provision of a novel method or process of constructing a 15 rug through the medium oi. a sewing machine wherein a plurality of strands of yarn are piled transversely upon a at base, then stitched thereto, then cut intermediate the stitching, and wherein the ends of the cut yarn are then picked to form a nap, and a border is finally placed at each end of the rug.

Other objects and advantages of the present invention will appear throughout the following specification and claims.

In the drawings:-

Figure 1 is a top plan view illustrating the preliminary step of the process for constructing the rug, showing the strands piled ltransversely of the base;

the rug is rolled up after the loose strands of yarn have been distributed to a uniform thickness transversely ofthe base;

Figure 6 is a top plan view .of the rug illustrating the third stage in the process and showing the preliminary rows of stitching down through the center and adjacent the marginal side edges of the rug Figure 7 is a bottom`plan view of the rug as shown in Figure;

lFigure 81s a transverse on line 8 8 of Figure 6;

Figure 9 is an enlarged fragmentary sectional view taken online 9-9 of Figure 6;

Figure 10 is a top plan view of the rug yillustrating the fourth step inthe process, wherein the strands vhave been completely stitched transversely throughout their-length to the base, and illustrating the manner in which the marginal side edges constituting the fringe are trimmed Figure 2 is a fragmentary enlarged top plan` sectional view taken Figure 11 is a bottom plan view of the rug after the marginal side edges have been trimmed;

Figure 12 is a transversey sectional View taken on line |2-I2 of Figure 11;

Figure 13 is a top plan view of the completed rug;

Figure 14 is an enlarged fragmentary top plan view of a portion of one corner of the rug;

Figure 15 is a fragmentary enlarged longitudinal sectional view taken on line |-I5 of Figure 14;

Figure 16 is a fragmentary transverse sectional view taken on line I 6-l6 of Figure 14, and also illustrating a fragment of a cutting knife used for cutting the transverse strands intermediate the rows of stitching extending longitudinally of the rug;

Figure 17 is a fragmentary transverse sectional view somewhat similar to Figure 16A and illustrating the manner in which a carding device may be used for creating or forming a nap by catching the lose ends of the cut yarn;

Figure 18 is an enlarged fragmentary plan view of one corner of the rug.

By referring to the drawings it will be seen that 20. designates the base or backing of the rug which preferably consists of a flat piece of heavy canvas or other similar material, to provide a sturdy and durable base. The cut edge of the fabric or canvas base or backing may be folded under to provide a hem 2| extending around one side and the ends, if desired, to prevent the fraying of the fabric base or backing. One edge may be a selvage edge, but if not, the raw or cut edge may be similarly hemmed without departing from the spirit ofthe invention.

In carrying out the invention and producing the ultimate article, the backing or base 20 in the desired size and shape is placed upon a ilat table, and strands of cotton dyed yarn 23,y or other material, preferably two-ply, of proper length slightly longer than the transverse-'width of the base 20, are piled upon the top face of the base or backing 20, as shown in Figures 1 to 4, inclusive. 'I'he loose Ystrands of yarn are properly distributed to a desired vthickness and at a uniform thickness upon the base. This constitutes the first step of the process.

The strands are then rolled up with the base in the manner as shown in Figure 5 to form a roll, in this way piling the yarn and slightly compressing the same to hold the strands in' a compressed or mat-like formation, this being the second step in the process. By having the mat rolled, thesame may be easily handled and moved to the stitching machine. Y

'I'he mat or rug is vthen unrolled and through vthe medium of a regular sewing machine constructed to stitch two rows of stitching simultaneously, the parallel'rows of stitching 24 are sewed through the longitudinal center of the rug or mat, as shown in Figure 6. The parallel rows of stitching 25 and 26 are then sewed along 4the longitudinal si'cle edges of the rug or mat,

these rows of stitching 24, 25 and 26 extending transversely of the strands of yarn and longitu- -dinally of the base 20 of the mat or rug-note .particularly Figures 6 and '1. 'I'his constitutes the third step of the process. Thus, it will be seen that through the medium of the.. parallel rows ofstitching 25 and 26, longitudinal rows of side fringe 21 and 28 are provided along the side edges of the mat or rug, as shown in'Figure 6. The machine employed for stitching the strands to the base or backing is so constructed as to sew two lines of stitching at a time. The third step in the process, described above, comprises stitching two parallel central rows of stitching and 'then two separate sets of rows of stitching adjacent the longitudinal side marginal edges of the rugs.

The strands 23 are then stitched in proper spaced relation by simultaneous parallel rowsof stitching to provide rows of stitching indicated by the numeral 29, this being the fourth step in the process or method. 'Ihis method will facilitate the securing of the yarn in an even tautness throughout the length of the yarn.

It should be understood that through the medium of the parallel rows of stitching extending transversely of the yarn strands and longitudinally of the base or backing of the rug, there will be a row of stitching, or a seam about every ve-eighths of an inch, it being understood that the present invention is not limited to this particular measurement of distance between the rows of stitching. The marginal fringes 21 and 28 formed along the sides of the rug are then cut along their outer edges to provide yarn strips, each strip being approximately one and threequarters inches, or two inches, in depth, indicated by the numeral 30, which strips are then sewed at right angles to the strands 23, as shown in the enlarged view in Figure 15, and in top plan view in Figures 13 and 14. A pair of spaced parallel rows of stitching 3| is provided extending transversely across the ends of the rug to provide end fringes 32, the inner'cut edges of .the strips 30 abutting against the strands 23 in the manner as shown in Figure 15, in this way providing a decorative, as well as a binding end finish for the rug at each end thereof. 'I'he depth of the fringes 21 and 28 will then be slightly shorterl along the sides of the rug than it was originally. This constitutes the fifth step ofthe process. 'I'he edges of the fringes 32 and the edges ofthe fringes 21 and 28 in each instance, preferably slightly overhang the `marginal edge of the base or backing 20 to efliciently bind the base or backing 20 and to constitute an attractive and durable nished marginal border around the rug.

The transverse strands 23 are then cut transversely intermediate the rows of stitching 24, 25, 26 and 29 through the medium of a cutting knife 33 of any suitable or desired construction, which constitutes the sixth step in the method. A conventional cutting knife is illustrated in Figure 16, but it is not desired to limit the particular type of cutting knife employed in this step of the process. The knife will cut completely through the strands 23 down to the base or backing 20 without cutting the backing or base 2li itself.

Because of the method of stitching descri above, the yarn when cut will provide strands vof substantially the same length and also provide an even top face for the rug, due to the fact that the strands are anchored intermediate the ends and near the ends before the other intermediate rows of stitching'are added.

After the strands 23 have been cut transversely, as described above, through the medium of the knife 33 of any -suitable or desired structure, the rug is then run under a machine having a plurality of pickers 35 somewhat in the nature of a cotton picker, the pickers having small hooks upon their ends to catch in the loose cut ends of the yarn and to create or form a nap over the outer or upper face of the rugby roughening up the top surface of the rug, this constituting the seventh or last step of the process, thereby producing the finished product.

'I'hrough the medium of the process above described, it will be seen that a rug maybe made on va. sewing machine and not upon a loom as is usually the case in connection with other manufactured rugs. Qne well-known method of producing rugs is by sewing on buttonsor lmobs of yarn, this constituting a very complicated and expensive procedure or method. By employing the present process the rug may be made on a handsewing machine, the steps being very sim.-l

ple to follow and the finished product being produced very quickly and cheaply. The rows of stitching upon the back or base and the overhanging of the fringe at the edges will tend to render the rugv anti-skid and will tend to resist slipping on the iioor. The nap upon the upper face of the rug will also provide a soft tread and give the appearance of a Woven or loom-made rug which Awill be very durable and present a pleasing appearance. Furthermore, the rug because of its sturdy construction will .tend to launder well and hold firmly together under severe usage, as well as during the laundering thereof. Y'

By means of the process above described, it will be seen that there is produced a rug embodying a base or backing 20 having longitudinally extending kerfs or cuts 34, the cuts extending transversely of the strands 23, the strands being rmly stitched to the base or backing intermediate the kerfs or cuts 34, and in this way providing a multitude of cut endsof yarn strands which, because of the picking step, will tend to stand up and provide a fuzzy nap in substantially parallel longitudinal rows throughout the length of the rug, the ends of the yarn being close together to provide a substantially solid mass throughout the completed area of the rug giving the effect of a deep-pile of yarn. The rug is also provided with side longitudinal rows of fringe 21 and 28, and end rows of fringe formed by the transverse strip 3D which is stitched across each end of the backing or base 20, at the respective sides of the rows of yarn strands 23. 'I'he base or backing 20 in the initial or first step of the process, extends beyond the transverse strands of yarn 23, as shown in Figure 10, to

provide an extension yledge 36 to which the strips 30 may be secured as previously described.

From the foregoing description it will 'be seen that a very efilcient process or method of producing rugs through the medium of a simple sewing machine has been provided wherein the work may be done byhand on a regular sewing machine to sew two rows of stitching at one time in predetermined spaced relation to ilrmly an- 6. A method of making rugs, mats and the like chor the transverse strands of yarn to a. base or backing and further form a row of fringe around the entire edge of the rug and then by cutting the strands in between the rows'of stitching provide a thickly piled nap for producing a soft, durable and attractive appearing rug. It should be further understood of course that it is not desired to limit the present invention to any particular size or shaped rug or mat, and any suitable type or color of yarn, or other material, may be substituted without departing from the spirit of the invention.

From the foregoing description it will be further understood that not only a simple and eilicient process for producing a rug has been provided but also a very attractive and durable as well as inexpensive rug or mat has been produced.

'I'he method and structural features may be slightly modified so long as these modifications fall within the scope of the appended claims.

Having described the invention, what I claim as new is:-

l. A method of making rugs, mats and the like, which consists in extending strands of yarn transversely of a fabric full length thereof, then stitching the yarn transversely to the base by means of central stitching extending longitudinally of the base, then stitching the yarn also to the base by means of stitching extending longitudinally of the base near the side edges of the base,-and then stitching the yarn to the base by means of other rows of stitching extending longitudinally of the base between the rst mentioned rows, to provide an even tautness of ther yarn between the various rows of stitching, and then cutting the yarn intermediate the rows of stitching.

2. A method of making rugs, mats and the like which consists in extending strands of yarn transversely of a base, then stitching the strands to the base by means of longitudinal spaced rows of stitching extending transversely of the strands of yarn, allowing the ends of the strands to extend beyond the side edgesof the base to form a longitudinal fringe, then trimming the fringe to provide a detached fringe strip, and then stitching the detached fringe strip to thebase transversely across the transverse ends to provide end fringe.

3. A method of and process for making rugs, mats and the like which consists in extending loose strands of yarn transversely across a iiexible base, backingand the like, then patting, pressing and spreading the loose strands of yarn substantially the full length of the base and transversely thereof until the strands are properly distributed to a desired uniform thickness, then rolling up the strands with the base for cornpressing the yarn upon the base evenly throughout the length of the strands, then unrolling the same, and then stitching the strands to the base by spaced rows of stitching which extend transversely of the strands and longitudinally of the base.

4. A method as defined in claim 3 with the additionall step of cutting the strands transversely intermediate the rows of stitching.

5. A method as dened in claim 3 with the ad-l1 ditional steps of cutting the strands transversely intermediate the rows of stitching, and then picking the cut ends of the strands to provide a nap upon the'face of the rug.

base for substantially the which consists in extending strands of yarn transversely of a base, then stitching the strands to the base by means of longitudinal spaced rows of stitching extending transversely of the strands of yarn, allowing the ends ofthe strands to extend beyond the side edges of the base to form a longitudinal fringe, then trimming the fringe strip, then stitching the detached strip tol the base by a plurality of spaced rows of stitching transversely across the transverse ends of the base, extending the inner edges of the fringe strip close to the first mentioned strands, and extending the opposite .ends of the fringe strip beyond the ends of the base to provide an end fringe.

7. A method of making rugs, mats and the like which consists in extending strands of yarn transversely of a base, then stitching the strands to the base by means of longitudinal spaced rows of stitching extending transversely of the strands of yarn, allowing the Vends of the strands to`ex a longitudinal fringe, then trimming the fringe strip, then stitching the detached strip to the base by a plurality of spaced rows of stitching transversely across the transverse ends of the base, extending the inner edges of the fringe strip close to the first mentioned strands, extending the opposite ends of the fringe strip beyond the ends of the base to provide an end fringe, and then cutting the strands of yarn mid-way between the rows of stitching.

8. A method of making rugs, mats and the like which consists in extending strands of yarn transversely of a base, then stitching the strands to the base by means of longitudinal spaced rows of stitching extending transversely of the strands of yarn, allowing the 4ends of the strands to extend beyond the side edges of the base to form a longitudinal fringe, then trimming the fringe strip, then stitching the detached strip to the base by a plurality of spaced rows of stitching transversely across the transverse ends of the base, extending the inner edges of the fringe strip close to the rst mentioned strands, extending the opposite ends of the fringe strip beyond the ends of the base to provide an end fringe, then` cutting the strands of yarn mid-Way between the rows of stitching, and then picking and carding the cut ends of the strands to provide a nap.

9. A rug, mat and the like comprising a base, a plurality of closely arranged longitudinal rows of transversely extending strands of yarn, longitudinal rows of stitching securing said strands to said base, the ends of the yarn extending outwardly of the base and providing a nap, an end strip extending transversely of the base and transversely across the ends of 'the longitudinal rows of transversely extending yarn, the end strip comprising strands extending longitudinally of the base and at right angles to the strands in the longitudinal rows, the inner ends of the strands of the end strip abutting the ends of the longitudinal rows of transversely extending strands, and parallel spaced rows of stitching extending transversely of the strands of the end strip and transversely of the base for securing the end strip in place and providing a reinforcing binder against the ends of the longitudinal rows of transversely extending strands.

WILLIAM W. ROBINSON.

' tend beyond the side edges of theba'se to form 

